Gear and method of making



July 2 1940- E. U.-T. BERTHELSEN 2,206,831

i GEAR AND METHOD OF MAKING u Filed uam v, 1938 N sawagmemmnummm.munmmmMWm f A'ITORNEY5.

3E 66 6 INVENT OR uu|m\\x.mm\ Mgr/hard ameri/wm Patented July 2, 1940 UNITED sTATEs PATEN T OFFICE Gaan AND METHOD 0F MAKING Erhard U. anmachen, chicago, nl., assignor tu Illinois Tool Works, Chicago, lll., a corporation of :Illinois Application March 7, 1938, Serial No. 194,256 I 14 Claims.

l helical or worm gears must, in order to properly intermesh with the `helical tooth on the helical Vor worm gear, b e` provided with teeth extending' in lines angularly 'arranged with respect to the axis of the gear. gears of this type lo are often provided with acurved throat when machined from a relatively thick blank. The production of gears having teeth so congurated has heretofore necessitated the forming of the Vtooth portions by relatively slow and costly machining operations such, for example, as by gen erating the teeth by` the hobbing process.

It is an object of the present invention to provide an, improved and simplified gear of the above class. as well as a method for forming the gear which obviates the above difficulties and permits the manufacture of' the gears `by simple, expeditious and inexpensive forming operations.

The invention` more specifically contemplates` the provisionv of amethodfor forming a gear of g5," the above type by a stamping or pressing operation-which notonly conflgurates the gear and l, shapes the .teeth to theQproper sectional form,v

helical gearing which eliminates backlash.

Numerous other objects and Aadvantages will,` be more apparentfrom the following detailed description when considered in connection with n the accompanying drawing. wherein-- Flg. 1 is an elevational view of a device embodying'the principles of `the `present invention;

Fig. 2 is a sectional elevation taken on the line 2--2 in liig.1;v i' V Fig. 3 is a detail elevational view of the lower portion of the worm wheel in Fig. l and showing the teeth configuration more in detail;

Fig. 4 is a plan view taken on the line l-fl in Fig. 3;

Fig. 5 is a detail sectional plan view taken on the line 5-5 in Fig. 1; y

Fig. 6 isa sectional detail view indicating the method of conflgurating the gear teeth, and showing a portion 'of suitable die members in operative position prior to shaping the teeth; and

operative intermeshing with the mating helical Fig. 'I is a sectional line 'l--l in Fig. 1. i A Referring to Figs. l to 5 of the drawing, wherein there is disclosed more in detail one preferred embodiment constructed in accordance4 with the present invention, it will be seen there is displan*v view taken on the closed a set of operatively intermeshing gears;

comprising the worm gear, I0 and the worm foljlower indicated generally by lthe numeral I2. 'Ihe worm gear I0 constitutesthe driving member and is mounted upon the l"drivingshalt 4I4 through the agencyl of a set screw i i6, the shaft `being rotatably journaled in'ya` 'bearing aperture in the flange I8 of the` bracket member indicated generally by the reference numeral 2 0. A

The bracket member is providedwith a Second ilange 22., generally parallel and'coextensive with l the `flange I8. 'Ihe 'ange 22 threadedly mounts the adjustable threaded pintle 2l in coaxial alinement withtheshaft il, thei-pintle having atapered end 26 adapted to center,V and rotatably support the adjacent end of the wormgear, as clearly shown in Fig. 1. A suitable jam nut 28 permits the pintle to be locked in adjusted. posi-g tion so that the worm will' be constrainedv for rotation about a fixed predetermined axis. Attention is Specifically directed to thefact that the worm gear I0, being a form of helical gear, has threads' which at'any point make a :definite angle with a `plane normal to the axis of the gear. This angleis generally known as the helix angle and is indicated by the letter A in Fig. 2. As is well-known to those skilled in the art, the helix angleis'the angle made by the thread at its pitch diameter and it therefore substantially corresponds with the angle-made by the flank of the tooth at a corresponding radial position. .As is further well-known and illustrated in detail in Figs. l and 5 of the present drawing, the angle made by the flank surfaces of the helical worm tooth with a plane normal to the axis of the worm varies radially between the root and the crest of the tooth.

A Worm wheel, to properly intermesh with the tooth orthe teeth of the worm l2, must have peripheral tooth portions which extend in the same direction as the intemeshing tooth portions oi the worm.' In other words, the teeth 30 on the Worm gear I0, can only be properly engaged when the worm wheel is provided with teeth having flanks which lie in parallel juxtaposition with the flanks of the teeth 30 at all points of intermeshing engagement. Accordingly, therefore, the Worm Wheel i2, asclearly shown in the figures, comprises a pairof parallel 2. gear members 32 which have teeth inclined withrespect to their plane. It will be noted that the as viewed in the figure, while the line C represents plane, as clearly shown in Fig. 2. The relative position of the at body of the gear with respect vto the tooth portions thereof is further indicated by the dotted lines 32 in Fig. 5. The gear teeth 34 onthe periphery of the gears 32 have a cross-sectional, form corresponding to that of conventional gear teeth, and extend generally transversely of the thickness of the sheet of material forming the gears. Attention is particularly directed to the fact, however, that each of the gear teeth 34 is twisted, displaced'or warped-bodily out of the plane of the gear. Thus, in Fig. 4 the line B represents the central plane of the upper gear 32,

a plane passing through the gear tooth normally thereto and midway between the extremities 1 thereof at thepitch circle; Accordingly, it will be noted that the planes B and C intersect at the angle A, which is identical with the aforementioned'angle A of the worm.Y The foregoing more or less diagrammatically illustrates the manner -form the `angle A with the axis of the gear, which may be represented by the line E in Fig. 4.

The gears 32 are mounted upon the rotatable shaft 36 for rotation therewith. In the embodiment shown, it will be evident that the axis of the shaft 36 is parallel with any plane normal to the `axis of the worm I0. Accordingly. the teeth 34 and the flanks or working surfaces thereof necessarily extend in the same direction as the teeth 30 when they are in intermeshing engagement, as shown in Fig.` 1, and in such position the juxtaposed working surfaces will likewise be in parallel engagement. (See Fig. 5.)

It Yis particularly important to note that the twisting of the `tooth with respect to the plane of the gear 32 is progressive, beginning adjacent the root portion of each tooth. That is to say, each of the teeth is warped so that the angle A made by its flank increaseswith the distance from the central axis of the gear. This is clearly shown in Fig. 4 whereingitwill be noted that beginning with the root portion of the center-# most tooth the iiank surfaces have a correspondingly increased inclination as they progress toward the peripheral extremity of the gear tooth.

, 'I'his construction lis also clearly evident in Fig. 3.

engage with` a worm gear having teeth of true helical form. Thus it will be 4understood that merely bodily twisting the gear teeth he same angle throughout their radial extent cannot possibly suffice to correlate their contact surfaces with those of a worm gear having true helical provided with a pair of apertures 62 shown clear- 'ly in Fig. 1. It will be noted that theapertures proper conformation with the mating tooth surfaces.

The gears 32 lend themselves readily to manu- Afacture by means of a punch press. When proceeding in accordance with the preferred method, each of the gears may be pressed or stamped through the agency of such a press, using a pair of dies havingappropriate cutting surfaces to sever the periphery of the blank in the form of the gear teeth disclosed and in addition, if desired, in the same operation to make theapertures in the plate, to be hereinafter described more in detail. It is thought that the nature of such a die will be obvious to anyone skilled in the art. As a second step in the process, the gear blanks so formed are placed in' a second die, more or less diagrammatically disclosed in Fig. 6, wherein the numeral 38 indicates a portion of the lower die, and 40 a corresponding portion of the upper die, which will be suitably supported and actuated by a press (not shown).` The lower die is provided with a series of V-shaped depressions 42, co,- extensive with each of the' teeth 34 of the gear blank 32, and having a surface inclined at'the angle A with respect to the flat surface of the die. The upper die 40 is provided with projections which correspond to and mate with the depressions 42.

In carrying out this method the gear blank will be situated so that the teeth 34 reside directly above' the surfaces 44. Accordingly, when the upper die is actuated downwardly under pressure, each of the teeth will be bodily twisted through Vthe predetermined angle A to produce the nal" gears, the dies 38 and 40 being preferably so configurated as to blank. ,s i Y While this process involvesl two separate operations, it will be obvious from the above disclosure that these may be combined so that the operation of twisting the teeth, as well as the blanking 'of the gear teeth, will be carried out coincidentally through the agency of a single combination progressive die. g,

'I'he gears 32 are mounted upon the shaft 56 36 through the agency of the bushing 48 positioned by a set screw 50. The right-hand gear 32, as viewed in Fig. 2, is rotatably mounted upon an annular shoulder 52. The left-hand gear 32, as viewed in the figure, has a relatively smaller central aperture engaging the annular portion 54 of reduced diameter, and the end56 of the bushing is headed over or upset to rigidly'mount this latter gear in the position shown. A tongue or lug 58 projects inwardly from the periphery of the central aperture 54 to theperiphery of the shaft 36 through a suitable mating slot 60 extending radially of the bushing. lAs a result, the fixed gear is effectively positioned against inadvertent rotation with respect`to the bushing 48 at any lo time. r

In order to take up and prevent backlash in the gear train, each Aof thegears 32 is further unaiect the remainder of the on the adjacent gearsv `l! are identical in shape. form and position and are provided for support-4 ing and positioning the sheet spring member M. It is to ,be noted that the spring member 64 is made out of a fiatl strip of spring stock having a pair of spaced fingers 0I at either end forming bifurcations adapted lto engage along opposite sides of the gears 32 to retain the spring in theoperative position shown clearly in Figs. 1, 2 and.7. From a consideration of the topmost apertures 82, shown in Fig. l, it will be apparent that thelower edges thereof comprise portions 68 which are coincidental with a circle having a radius R whose center is the axis of the gears 32. 'I'he upper edges `12 of the aforementioned apertures i2 reside in a circular curve which intersects the curve of the edgesl in two places.

As shown in the drawing, the ends of the bowed springs 64 bear oppositely against the edges `12 at `substantially the points where they intersect with the lower edges 68 so that, when the gears 32 are relatively displaced with respect to each other, the springs will exert an equal and opposite force upon both of the gears, tending to return them to the` position' where the apertures 62 are in congruence.

During any relative movement of the gears, the bifurcated ends of the springs 64 will slide with respect to a portion of the `edges Il of each of the apertures il. Attention is respectfully Vdrawn to the fact, however, that in view of the location of the edges 68 in a line having a center coincident with the axis of the gears, any frictional resistance to rotation will be identically the same in both directions.

The lower edge of the apertures 62 is further provided with a central, inwardly extending tongue or lip 10 preferablyhaving an edge par` allel tothe aforementioned curved edge 12.. One important function of this tongue portion 1I is -to prevent damage to the springs Il by too great a relative`shifting of the gears 32. In other words, these lgears can` never be rotationally shifted greater than a distance quivalent to the unbroken lengthof each of the segmental edge portions 68. To state the same function in other words, the ends of the springs I4 may be moved together only until they contact the tongue portion 1li at which point they will be effectively stopped.

According to the preferred form of the present invention the springs t4 are made of spring tempered flat spring steel and are assembled as shown by alining the respective apertures 62 and in` serting the springs into position after they are bent to substantially conform with the curve of the edge 12. The springs 64 are, accordingly, due to the configuration' of the apertures, retained always in the bowed position shown so that they exert opposite expansive stresses upon the gears.

In order tdv employ,` thisstructure to prevent ing'intermeshed `withfthe worm Il, are relatively rotated a short distance'l from the normal posi'- tion wherein theadjacent apertures are in alinei 'I'his effect is clearly shown 4,in Fig. 5 wherein attention is directed vtothe fact that theflank 1I" of the lower gear 32, as'viewed in the n gure, isA

3 parallel with the adjacent face of the angularly extending tooth 30, while at the same time the flank 16 of the upper gear 32 contacts the flank of .the adjacent tooth Ilin exactly the same angular relationship, both contacts being made under the influence of` an v,equal and opposite reaction, v i

The present invention provides asimple and effective gear, `as well as an expeditious and ini- `expensive method for forming the gearv for use in intermeshing engagement with a second gear having a helical thread. While the above illustrated disclosure has been directed primarily to va combination of\ worm gear and worm wheel,

it willbe apparent to those skilled in the art that it'is likewise adaptable to various other types of so-called helical or spiral gearing which may comprise central shafting` arranged atl various angles and relationships.

Numerous changes may be made in the form.

.with respect to the plane of the body portion of the gear, progressively between the -rooty and crest portions thereof. 2. The method of providing a gear adapted to mesh in operative relationship with a second gear adapted to be positioned with respect thereto andhaving ahelically arranged tooth, which comprises providing a flat blank, subjecting the blank to a pressing operation to form transversely extending gear teeth on the periphery thereof, twisting each gear tooth, with respect to the planey ofthe body portion of the gear,l progressively between the root and crest portions thereof.

3. The method of providing a gear adapted to mesh in predetermined operative relationship with a second gear having helically arranged teeth, which comprises providing a fiat blank of material having gear teeth thereon extending transversely of said fiat blank, twisting each gear tooth with respect tothe plane of the body4 portion of the gearprogressively'between the root and crest portions thereof.

4. The method of providing a gear adapted to mesh in predetermined operative relationship with a second gear having helically arranged teeth, which comprises providing a sheet blank of material, subjecting said `sheet material `to a stamping operation to forxn a substantially fiat gear -having generally transversely extending.v radial gear teeth on the periphery thereof, and

twisting each gear tooth with respect to thev plane of the body portion of the gear, progressively between the root and crest portions thereof.

5. The method of providing a gear adapted tol t mesh in predetermined operative relationship with a worm gear having ahelically arranged tooth, which comprises providing 'a blank of sheet material, subjecting said sheet material to a stamping operation to form a substantially ilat gear having substantially radially extending u.

said intermeshing gear having gear teeth formed gear teeth on the periphery thereoi,l said teeth being generally coextenslve with the thickness of the sheet material, twisting each gear tooth with respect to theplane of the body portion of the gear, progressively between the root and crest portions thereof.

6. In combination, 'a helical gear having at least one gear toothl arranged in a substantially helical path on the periphery, thereof, an` intermeshing gear associated with the helical gear.,

on the periphery thereof and arranged generally transversely to the plane of the gear, said teeth being twisted with respect to the plane of the4 body portion of the gear in such a manner that each tooth twists progressively` between the root and crest portion thereon' '1.'In combination,. ahelical gear having at least one gear tooth arranged in a helical path on the periphery thereof,- an intermeshing gear associated with the helical gear, said gears having xed spaced axes, .said intermeshing gear having gear teeth formed on the periphery there- `of and arranged vgenerally transversely to its plane, each tooth of said intermeshing gear being twisted with respect to the plane of the bodyportion oi the gear in such a manner that each tooth twists progressively between the root and crest portion thereof.v

8. In combination, a helical gear having at least one gear tooth arranged in a substantially helical path, an` intermeshing gear having an axis spaced, from the axis ofsaid helical gear, said intermeshing gear being arranged in aplane intersecting said gear tooth oi the helical gear and making an angle 'of less than 90 ,degrees witha line normal to the said gear tooth at the point of intersection, gear teeth formedon theperiphery of'said intermeshing gear and extending vgenerally transversely 'to the plane' of the gear, said teeth being twisted with respect to the plane oithe body portion of the gear in such a manner that each tooth twists progressively be Y. tween the rootandcrest portion thereof.

9. In combination, a. helical gear having at least one gear toothv arranged in a substantially helical path, an intermeshing'gear, said intermeshing gear being arranged in a plane intersecting said gear tooth of the helical gear and making an angle oi less than 90 degrees with a lineA normal to the said gear tooth-at the point of intersection, gear teeth formed on the periph- 'ery of said intermeshing gear and extending generally transversely to the plane of the gear, said teeth being twisted with respect to the plane of thebody portion vof .the gear in .such aymanner` that each tooth twists prvely between the root and crest" portion thereof.

10. A gear having peripheral, generally radially extending gear teeth formed thereon and extendiriggenerally transversely-tothe plane of the gear, said teeth being progressively twisted about their' radial axes in a extending from the root to the y 11. A gear having peripheral,` generally radial-V 1yextending gear teeth formed thereon andentending generally .transversely to the plane of the gear, said teeth being progressively twisted, r abouttheir radial axesin adirection extendingfrom the root to the crest. 1

1-2. In combination, a gear, a pair of coaxiallyv arranged gears intermeshing with said rst named gear, means to prevent backlash between y said gears, said backlash preventing means com'- prising apertures in said coaxial gears, one edge oi each aperture being substantially in a curve formed about the axis of said coaxial gears as a center, and a bowed spring varranged in said apertures, the ends oi said spring being bifurcated and oppositely engaging said edges to retain the spring in said. position, each' aperture 'having opposed side edges-intersecting said rst named edge against which the spring reacts lto urge the gearsoppositely" whereby to cause the teeth of said coaxial gears to reactgrelatively oppositely against the engaging tooth flanks of said nrst named gear.

13. A gear constructionior 'use in a gear train tov prevent backlash and comprising a pair of coaxially intermeshing gears apertures in -both of said coaxial gears, one ed'geiof each aperture being substantially in a curve formed about the axis of said coaxial gearsas a center, and a bowed spring arranged in bothvoi said apertures,

the ends of said spring sndably engaging 'said 'edges to retain the spring in said -positioneach being substantially in a curve formed about the axis of said coaxial gears as a center, .and a bowed spring arranged in both or'said apertures,

the ends of said spring slidably engaging said edges to retain the spring in said position, the

intermediate portions of said spring being spaced from said edges, and means located a-predetermined point on each of said first vnamed edges against which the spring reacts to urge the gears oppositely. whereby to cause the teethl.- of saidcoaxial gears 4 vto react relativelyoppositely against the tooth flanks o! an intermeshing gear.

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